Fiber blends with improved moisture management properties

ABSTRACT

Fiber blends having hydrophobic fibers of both multiple staple lengths and multiple deniers of a single composition are disclosed. Yarns, fabrics, garments, and linens comprising the fiber blends with improved moisture management properties are also disclosed. Fabrics formed from the fiber blends have a water release rate at least about 10% greater than a comparative fabric that is compositionally identical but whose hydrophobic fibers are not both of multiple staple lengths and multiple deniers.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Application No. 61/914,080 filed Dec. 10, 2013, the entire disclosure of which is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention generally relates to fiber blends and yarns and fabrics produced therefrom. More particularly, the invention relates to fiber blends and yarns and fabrics produced therefrom, which have improved moisture management (water release rate, wicking, and drying time) properties.

BACKGROUND OF THE INVENTION

Fast drying fabrics comprising cellulosic yarns provide garment benefits in the areas of active sports, outdoor work, recreational activities, military and other uses for example, where the rate of perspiration is high. In some cases, fabric is treated with a water resistant chemical to a degree that the entire fabric becomes water resistant or hydrophobic. In other cases, a blend of cellulosic and synthetic yarns is incorporated into the fabric to provide improved water resistance and in some configurations, more rapid drying rates. These fabrics, however, do not have the appearance, ability to wick quickly, or comfortable feel of untreated cellulosic fabrics. In addition, these fabrics are typically treated with a hydrophobic chemical, or are blended with a synthetic fiber or hydrophobic treated yarn that does not absorb water, which reduces the overall ability of the fabric to absorb water compared to an untreated fabric. These fabrics, therefore, do not absorb water to the degree of an untreated cellulosic fabric. Thus, these fabrics do not sufficiently absorb water and are not well suited for drying applications, such as towels, for example.

Thus, there exists a need for a fiber blend that may be used in a fabric that has the appearance and feel of untreated cellulosic fabric, has a water weight gain similar to an untreated cellulosic fabric, is hydrophilic to provide wicking of sweat yet is fast drying. The fiber blends of the invention and the yarns, fabrics, garments and linens are directed toward these, as well as other, important ends.

SUMMARY OF THE INVENTION

The invention relates generally to fiber blends whose hydrophobic fibers have both multiple staple lengths and multiple deniers are disclosed. Yarns, fabrics, garments, and linens comprising the fiber blends have improved moisture management properties, including faster water release rates, wicking, and drying times.

One embodiment is directed to fiber blends, comprising:

about 0% by weight to about 15% by weight, based on the total weight of the fiber blend, of a hydrophilic component comprising at least one hydrophilic fiber; and

about 85% by weight to about 100% by weight, based on the total weight of the fiber blend, of a hydrophobic component comprising:

first synthetic hydrophobic fibers having a first composition; and

one or more optional second synthetic hydrophobic fibers having a second composition;

wherein at least a portion of said first synthetic hydrophobic fibers have multiple staple lengths and multiple deniers; and

wherein said first composition is different than said second composition.

A second embodiment is directed to fiber blends, comprising:

about 0% by weight to about 15% by weight, based on the total weight of the fiber blend, of cotton fibers; and

about 85% by weight to about 100% by weight, based on the total weight of the fiber blend, of polyethyleneterephthalate fibers;

wherein at least a portion of said polyester fibers have multiple staple lengths and multiple deniers.

A third embodiment is directed to fiber blends, comprising:

about 15% by weight, based on the total weight of the fiber blend, of cotton fibers;

about 75% by weight, based on the total weight of the fiber blend, of modacrylic fibers;

about 10% by weight, based on the total weight of the fiber blend, of nylon fibers;

wherein at least a portion of said modacrylic fibers, at least a portion of said nylon fibers, or at least a portion of both of said modacrylic fibers and said nylon fibers have multiple staple lengths and multiple deniers.

Another embodiment is directed to yarns, comprising the fiber blends described herein.

Yet another embodiment is directed to fabric, comprising the yarn described herein.

Other embodiments are directed to garment or linens, comprising the fabrics described herein.

Further embodiments are directed to methods of improving the moisture management properties of a fiber blend, comprising:

intimately blending:

about 0% by weight to about 15% by weight, based on the total weight of the fiber blend, of a hydrophilic component comprising at least one hydrophilic fiber; and

about 85% by weight to about 100% by weight, based on the total weight of the fiber blend, of a hydrophobic component comprising:

first synthetic hydrophobic fibers having a first composition; and

one or more optional second synthetic hydrophobic fibers having a second composition;

wherein at least a portion of said first synthetic hydrophobic fibers have multiple staple lengths and multiple deniers.

DETAILED DESCRIPTION OF THE INVENTION

The present invention can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, it is to be understood that this invention is not limited to the specific compositions, articles, devices, systems, and/or methods disclosed unless otherwise specified, and as such, of course, can vary. While aspects of the present invention can be described and claimed in a particular statutory class, such as the system statutory class, this is for convenience only and one of skill in the art will understand that each aspect of the present invention can be described and claimed in any statutory class.

The following description of the invention is also provided as an enabling teaching of the invention in its best, currently known aspect. To this end, those of ordinary skill in the relevant art will recognize and appreciate that changes and modifications may be made to the various aspects of the invention described herein, while still obtaining the beneficial results of the present invention. It will also be apparent that some of the benefits of the present invention may be obtained by selecting some of the features of the present invention without utilizing other features. Accordingly, those of ordinary skill in the relevant art will recognize that many modifications and adaptations to the present invention are possible and may even be desirable in certain circumstances, and are thus also a part of the present invention.

While the present invention is capable of being embodied in various forms, the description below of several embodiments is made with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiments illustrated. Headings are provided for convenience only and are not to be construed to limit the invention in any manner. Embodiments illustrated under any heading or in any portion of the disclosure may be combined with embodiments illustrated under any other heading or other portion of the disclosure.

Any combination of the elements described herein in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

Unless otherwise expressly stated, it is in no way intended that any method or aspect set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not specifically state in the claims or description that the steps are to be limited to a specific order, it is no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including matters of logic with respect to arrangement of steps or operational flow, plain meaning derived from grammatical organization or punctuation, or the number or type of embodiments described in the specification. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive.

All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited.

It is to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. In this specification and in the claims which follow, reference will be made to a number of terms which are defined herein. As employed above and throughout the disclosure, the following terms, unless otherwise indicated, shall be understood to have the following meanings.

As used herein, the singular forms “a,” “an,” and “the” include the plural reference, unless the context clearly indicates otherwise.

As used herein, the term “about,” when referring to a measurable value such as an amount, a temporal duration, and the like, is meant to encompass variations of ±10%, preferably ±5%, more preferably ±1%, and even more preferably ±0.1% from the specified value, as such variations are appropriate to achieve the improved woven fabrics and garments, unless other specified. As used herein, the term “about,” when referring to a range, is meant to encompass variations of ±10% within the difference of the range, preferably ±5%, more preferably ±1%, and even more preferably ±0.1% from the specified value, as such variations are appropriate to achieve the improved woven fabrics and garments, unless other specified.

As used herein, “fiber” means a unit of matter characterized by having a length at least 100 times its diameter or width and which has a definite preferred orientation of its crystal unit cells with respect to a specific axis. A fiber may be made of one or more continuous or very long filaments or shorter, cut portions or a combination thereof.

The term “yarn,” as used herein, refers to any assembly of the hydrophobic and hydrophilic fibers in a continuous strand that can be made into a textile material. In other words, the term “yarn,” as used herein, encompasses spun yarns and sheathed filaments, as well as other possible embodiments.

The term “staple length,” as used herein, refers to the average length of a group of fibers. Staple length depends on the origin of the fiber. Natural fibers (such as cotton or wool) have a range of lengths in each sample, so the staple length is an average. For synthetic fibers that have been cut to certain length, the staple length is the same for every fiber in the group.

The term “multiple staple lengths,” as used herein, refers to fibers that have at least two different staple lengths, wherein the difference between any two staple lengths is at least about 5%, preferably about 10%, more preferably about 15%, even more preferably, at least about 20%, and yet even more preferably, at least about 25%.

The term “denier,” as used herein, is a unit of measure for the linear mass density of fibers. It is defined as the mass in grams per 9000 meters of the fiber.

The term “multiple deniers,” as used herein, refers to fibers that have at least two different deniers, wherein the difference between any two deniers is at least about 5%, preferably about 10%, more preferably about 15%, even more preferably, at least about 20%, and yet even more preferably, at least about 25%.

The term “different,” as used in connection with fiber compositions, refers to:

-   -   at least two different polymer compositions, such as for         example, modacrylic and nylon;     -   at least two different ratios of polymerized residues in a         single polymer type, such as, for example, 90/10 copolymer and         50/50 copolymer; and     -   combinations thereof.         For any weight ranges in a copolymer, a difference is at least         about 1%, preferably at least about 5%.

As used herein, the term “polyacrylonitrile fiber” refers to a manufactured fiber of polymer resin containing residues of

either as a homopolymer or copolymer (such as with acrylates, methacrylates, styrene, vinyl chloride (modacrylic) and the like), and combinations thereof.

As used herein, the term “modacrylic fiber” refers to an acrylic synthetic fiber made from a polymer comprising primarily residues of acrylonitrile. Modacrylic fibers are spun from an extensive range of copolymers of acrylonitrile. The modacrylic fiber may contain the residues of other monomers, including vinyl monomer, especially halogen-containing vinyl monomers, such as but not limited to vinyl chloride, vinylidene chloride, vinyl bromide, vinylidene bromide, and the like. The types of modacrylic fibers that can be produced within this broad category are capable of wide variation in properties, depending on their composition. Some examples of commonly available modacrylics are PROTEX™, KANEKALON™, and KANECARON™ by Kaneka Corporation, PYROTEX™, and Formosa Plastics.

As used herein, the term “nylon fiber” refers to a manufactured fiber of aliphatic polyamides, including nylon-4,6, nylon-4,10, nylon-6, nylon-6,6, nylon-6,10, nylon-6,12, nylon-10,10, nylon-10,12, nylon-11, nylon-12, and the like.

As used herein, the term “polyester fiber” refers to a manufactured fiber of polymer resin containing ester functional groups in its main chain, such as such as polyethyleneterephthalate, polybutyleneterephthalate, poly(trimethylene terephthalate), copolymers thereof, and combinations thereof.

As used herein, the term “fluoropolymer fibers” refers to a manufactured fiber containing fluorocarbon-based polymer with at least one, but preferably multiple, strong carbon-fluorine bonds, including, but not limited to, polytetrafluoroethylene (PTFE), perfluoroalkoxy polymer (PFA), or fluorinated ethylene-propylene (FEP).

As used herein, the term “aramid fiber” refers to a manufactured fiber in which the fiber-forming substance is a long-chain synthetic polyamide in which at least 85% of the amide linkages, (—CO—NH—), are attached directly to two aromatic rings, including, but not limited to, para-aramid (p-aramid) and meta-aramid (m-aramid). Examples of para-aramids include, but are not limited to, (poly(p-phenylene terephthalamide), e.g., KEVLAR® (E.I. du Pont de Nemours and Company), TWARON® (Teijin Twaron BV), and TECHNORA by Teijin Company. KEVLAR is a para-aramid fiber having a very high tenacity of between 28 and 32 grams/denier and outstanding heat resistance. Examples of meta-aramids include, but are not limited to, (poly(m-phenylene isophthalamide), such as NOMEX® (E.I. du Pont de Nemours and Company) and CONEX® (Teijin Twaron BV). Preferably, the structural fiber is p-aramid, microdenier p-aramid. Such structural fibers feature excellent thermal stability and are virtually non-flammable. These fibers have a very high resistance to heat and are resistant to melting, dripping and burning at a temperature of at least 700° F. Moreover, their LOI value is preferably in the range of between about 28 and about 30.

As used herein, the term “melamine fiber” is a manufactured fiber in which the fiber-forming substance is a synthetic polymer composed of at least 50% by weight of a crosslinked non-thermoplastic melamine polymer of melamine units joined by methylene and dimethylene ether linkages. In the polymerization reaction, methylol derivatives of melamine react with each other to form a three-dimensional structure. This structure is the basis for the fiber's heat stability, solvent resistance, and flame resistance.

As used herein, the term “antistatic fiber” refers to a fiber, when incorporated into a fabric or other material, eliminates or reduces static electricity. Suitable fibers include, but are not limited to, metal fibers (steel, copper or other metal), metal-plated polymeric fibers, and polymeric fibers incorporating carbon black on the surface and/or in the interior of the fiber, such as those described in U.S. Pat. No. 3,803,453, U.S. Pat. No. 4,035,441, U.S. Pat. No. 4,107,129, and the like. Antistatic carbon fiber is a preferred antistatic fiber. One example of such conductive fiber is NEGASTAT® produced by E.I. du Pont de Nemours and Company, a carbon fiber comprising a carbon core of conductive carbon surrounded by non-conductive polymer cover, either nylon or polyester. Another example is RESISTAT® made Shakespeare Conductive Fibers LLC, a fiber where the fine carbon particles are embossed on the surface of a nylon filament. The yarns of both such fibers are available in a denier of at least 40. By way of example, a steel wire is available under the names BEKINOX and BEKITEX from Bekaert S.A. in a diameter as small as 0.035 millimeter. Another antistatic fiber is the product X-static made by Noble Fiber Technologies, a nylon fiber coated with a metal (silver) layer. The X-static fibers may be blended with other fibers, such as modacrylics, in the process of yarn spinning.

As used herein, the term “garment” refers to any article of clothing or clothing accessory worn by a person, including, but not limited to shirt, pants, underwear, outer wear, footwear, headwear, swimwear, belts, gloves, headbands, and wristbands, especially those used as protective wear or gear.

As used herein, the term “linen” (when not referring to the hydrophilic fiber) refers to any article used to cover a worker or seating equipment used by workers, including, but not limited to sheets, blankets, upholstery covering, vehicle upholstery covering, and mattress covering.

As used herein, the term “intimate blend,” when used in conjunction with a yarn, refers to a statistically random mixture of the staple fiber components in the yarn.

The fiber blends of the invention have hydrophobic fibers having both multiple staple lengths and multiple deniers within a single fiber composition for both single and multiple hydrophobic fiber compositions. Yarns, fabrics, garments, and linens comprising the fiber blends have improved moisture management properties, including faster water release rates, wicking, and drying times.

Accordingly, in one embodiment, the invention is directed to fiber blends, comprising:

about 0% by weight to about 15% by weight, based on the total weight of the fiber blend, of a hydrophilic component comprising at least one hydrophilic fiber; and

about 85% by weight to about 100% by weight, based on the total weight of the fiber blend, of a hydrophobic component comprising:

first synthetic hydrophobic fibers having a first composition; and

one or more optional second synthetic hydrophobic fibers having a second composition;

wherein at least a portion of first synthetic hydrophobic fibers have multiple staple lengths and multiple deniers; and

wherein said first composition is different than said second composition.

A second embodiment is directed to fiber blends, comprising:

about 0% by weight to about 15% by weight, based on the total weight of the fiber blend, of cotton fibers; and

about 85% by weight to about 100% by weight, based on the total weight of the fiber blend, of polyethyleneterephthalate fibers;

wherein at least a portion of said polyester fibers have multiple staple lengths and multiple deniers.

A third embodiment is directed to fiber blends, comprising:

about 15% by weight, based on the total weight of the fiber blend, of cotton fibers;

about 75% by weight, based on the total weight of the fiber blend, of modacrylic fibers;

about 10% by weight, based on the total weight of the fiber blend, of nylon fibers;

wherein at least a portion of said modacrylic fibers, at least a portion of said nylon fibers, or at least a portion of both of said modacrylic fibers and said nylon fibers have multiple staple lengths and multiple deniers.

Suitable hydrophilic fibers include at least one polymer selected from the group consisting of cellulose, cellulose derivative (such as cotton, viscose, linen, rayon, fire-resistant rayon, lyocell, or a combination thereof), wool, and copolymers thereof, and combinations thereof. Preferably, the hydrophilic fiber comprises cotton or fire-resistant rayon, or a combination thereof. In certain embodiments, the hydrophilic fiber is a cellulose derivative, including but not limited to, cotton, viscose, linen, rayon, or a combination thereof. In certain embodiments, the hydrophilic fiber is cotton, especially cotton that has not been treated with a fugitive fire resistant treatment.

Suitable hydrophobic fibers may include at least one polymer selected from the group consisting of polypropylene, polyester (such as polyethyleneterephthalate, polybutyleneterephthalate, poly(trimethylene terephthalate)), polyphenylene oxide, polylactide, nylon, polyacrylonitrile, polybenzimidazole, aramid, fluoropolymer, and copolymers thereof, and combinations thereof. Preferably, the hydrophobic fiber comprises polyester, polyacrylonitrile or copolymer thereof, nylon, or a combination thereof. More preferably, the hydrophobic fiber is polyester or a combination of modacrylic and nylon.

In certain embodiments of the fiber blend, said hydrophilic fibers are cellulose, cellulose derivative, wool, or a combination thereof.

In certain embodiments of the fiber blend, said hydrophilic fiber is cotton or rayon.

In certain embodiments of the fiber blend, said first synthetic hydrophobic fibers are fibers selected from the group consisting of polypropylene, polyester, polyphenylene oxide, polylactide, nylon, polyacrylonitrile, polybenzimidazole, aramid, fluoropolymer, and copolymers thereof.

In certain embodiments of the fiber blend, said at least one second synthetic hydrophobic fibers are present.

In certain embodiments of the fiber blend, said at least one second synthetic hydrophobic fibers are present and said at least one second synthetic hydrophobic fibers are fibers selected from the group consisting of polypropylene, polyester, polyphenylene oxide, polylactide, nylon, polyacrylonitrile, polybenzimidazole, aramid, fluoropolymer, and copolymers thereof.

In certain embodiments of the fiber blend, said first synthetic hydrophobic fibers are fibers selected from the group consisting of poly(ethylene terephthalate), nylon, and modacrylic.

In certain embodiments of the fiber blend, said at least one second synthetic hydrophobic fibers are present and said at least one second synthetic hydrophobic fibers are fibers selected fibers selected from the group consisting of poly(ethylene terephthalate), nylon, and modacrylic.

In certain embodiments of the fiber blend, said hydrophobic component is a single color.

In certain embodiments of the fiber blend, at least a portion of said first synthetic hydrophobic fibers comprise:

a first group of fibers having the same staple length and multiple deniers; and

a second group of fibers having the same denier and multiple staple lengths;

wherein a fiber in said first group may be a fiber in said second group.

In certain embodiments of the fiber blend, said first group of fibers and said second group of fibers are substantially the same color.

In certain embodiments of the fiber blend, at least a portion of said first synthetic hydrophobic fibers comprise:

a first group of fibers having a first staple length and a first denier; and

a second group of fibers having a second staple length and a second denier;

wherein said first staple length is different than said second staple length; and

wherein said first denier is different than said second denier.

In certain embodiments of the fiber blend, said first group of fibers and said second group of fibers are substantially the same color.

In certain embodiments of the fiber blend, said hydrophilic component is present at a level of about 10% by weight to about 15% by weight, based on the total weight of the fiber blend; and

wherein said hydrophobic component is present at a level of about 85% by weight to about 90% by weight, based on the total weight of the fiber blend.

In certain embodiments of the fiber blend, said first synthetic hydrophobic fibers comprise:

about 10% by weight to about 90% by weight, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a first denier;

about 10% by weight to about 90% by weight, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a second denier;

wherein said first denier is different from said second denier; and

about 0% by weight to about 80% by weight, based on the total weight of the first synthetic hydrophobic fibers, of at least one fiber having an additional denier different than said first denier, second denier, and any said additional deniers, if present.

In certain embodiments of the fiber blend, said first synthetic hydrophobic fibers comprise:

about 10% by weight to about 90% by weight, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a first staple length;

about 10% by weight to about 90% by weight, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a second staple length;

wherein said first staple length is different from said second staple length; and

about 0% by weight to about 80% by weight, based on the total weight of the first synthetic hydrophobic fibers, of at least one fiber having an additional staple length different than said first staple length, second staple length, and any said additional staple length, if present.

In certain embodiments of the fiber blend, said first synthetic hydrophobic fibers comprise:

about 10 weight % to about 90 weight %, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a first denier;

about 10 weight % to about 90 weight %, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a second denier; and

about 10 weight % to about 80 weight %, based on the total weight of the first synthetic hydrophobic fibers, of at least one fiber having an additional denier different than said first denier, second denier, and any said additional deniers, if present.

In certain embodiments of the fiber blend, said first synthetic hydrophobic fibers comprise:

about 10 weight % to about 90 weight %, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a first staple length;

about 10 weight % to about 90 weight %, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a second staple length; and

about 10 weight % to about 80 weight %, based on the total weight of the first synthetic hydrophobic fibers, of at least one fiber having an additional staple length different than said first staple length, second staple length, and any said additional staple lengths, if present.

In certain embodiments of the fiber blend, said first synthetic hydrophobic fibers comprise:

about 20 weight % to about 80 weight %, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a first denier;

about 20 weight % to about 80 weight %, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a second denier; and

about 0 weight % to about 60 weight %, based on the total weight of the first synthetic hydrophobic fibers, of at least one fiber having an additional denier different than said first denier, second denier, and any said additional deniers, if present.

In certain embodiments of the fiber blend, said first synthetic hydrophobic fibers comprise:

about 20 weight % to about 80 weight %, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a first staple length;

about 20 weight % to about 80 weight %, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a second staple length; and

about 0 weight % to about 60 weight %, based on the total weight of the first synthetic hydrophobic fibers, of at least one fiber having an additional staple length different than said first staple length, second staple length, and any said additional staple lengths, if present.

In certain embodiments of the fiber blend, said first synthetic hydrophobic fibers comprise:

about 20 weight % to about 80 weight %, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a first denier;

about 20 weight % to about 80 weight %, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a second denier; and

about 10 weight % to about 60 weight %, based on the total weight of the first synthetic hydrophobic fibers, of at least one fiber having an additional denier different than said first denier, second denier, and any said additional deniers, if present.

In certain embodiments of the fiber blend, said fiber blend is substantially intimately blended.

Another embodiment is directed to yarns, comprising the fiber blends described herein. In certain embodiments, said yarn is a spun yarn.

In certain embodiments, the yarn may optionally contain at least one antistatic fiber. In typical embodiments, the antistatic fibers(s) are present at about 0.1-2.5% by weight, based on the total weight of the fabric.

Yet another embodiment is directed to fabric, comprising the yarn described herein.

In certain embodiments, said fabric meets the requirement for flame resistance, as set forth in American Society for Testing and Materials Standard Performance Specification ASTM F1506.

In certain embodiments, said fabric has a water release rate at least about 5%, preferably at least about 10%, greater than a comparative fabric, as said fabric dries from 20% by weight water to 1% by weight water, when tested in accordance with a modified version of the provisional AATCC Gravimetric Drying Test Method (AATCC/MM TS-05); and

wherein said comparative fabric is compositionally identical to said fabric and whose hydrophobic fibers are not both of multiple staple lengths and multiple deniers.

In certain embodiments, said fabric has a water release rate at least about 5%, preferably at least about 10%, greater than a comparative fabric, as said fabric is dried from a condition of wet (padded) to less than 1% by weight water, when tested in accordance with a modified version of the provisional AATCC Gravimetric Drying Test Method (AATCC/MM TS-05); and

wherein said comparative fabric is compositionally identical to said fabric and whose hydrophobic fibers are not both of multiple staple lengths and multiple deniers.

In certain embodiments, said fabric has a drying time at least about 5%, preferably at least about 10%, faster than a comparative fabric from 20% by weight water to 1% by weight water in a controlled environment of 70° F. and 55% relative humidity (+/−5% relative humidity), when tested in accordance with a modified version of the provisional AATCC Gravimetric Drying Test Method (AATCC/ASTM MM TS-05); and

wherein said comparative fabric is compositionally identical to said fabric and whose hydrophobic fibers are not both of multiple staple lengths and multiple deniers.

Other embodiments are directed to garment or linens, comprising the fabrics described herein.

Further embodiments are directed to methods of improving the moisture management properties of a fiber blend, comprising:

intimately blending:

about 0% by weight to about 15% by weight, based on the total weight of the fiber blend, of a hydrophilic component comprising at least one hydrophilic fiber; and

about 85% by weight to about 100% by weight, based on the total weight of the fiber blend, of a hydrophobic component comprising:

first synthetic hydrophobic fibers having a first composition; and

one or more optional second synthetic hydrophobic fibers having a second composition;

wherein at least a portion of said first synthetic hydrophobic fibers have multiple staple lengths and multiple deniers.

The fiber blends, yarns, and fabrics may contain other components and treatments. For example, the fabric may contain anti-microbial and/or anti-odor components, such as, for example, triclosan, silver, and the like. The fabrics, garments, and linens may also be treated with a stain release agent or water repellant on the outside surface of the fabric to reduce overall absorbency of the warp yarn, thereby further improving moisture management. Suitable stain release agents and water repellants include conventional fluoropolymers and silicone polymers (such as EPIC by Nextec and DWR from Xeromax).

The methods of preparing yarns of the various embodiments are well known in the art. See, for example, the discussions in T. Ishida, An Introduction to Textile Technology, published by Osaka Senken Ltd., Osaka, Japan (1991) or J. H. Marvin, Textile Processing, Volume 1, South Carolina State Department of Education (1973), the disclosures of which are herein incorporated by reference.

The yarns of hydrophobic and optional hydrophilic fibers can be made into a textile material or fabric by conventional means, such as weaving and knitting. Non-woven fabrics may also be made from the blended fibers. Other fibers may be incorporated into the fabric to obtain desired properties. For example, the fabric may contain about 5% by weight to about 10% by weight, based on the total weight of the fabric, of a continuous elastomeric filament, such as those products sold under the trade names of Lycra (Invista), Elaspan (Invista), Acepora (Taekwang), Creora (Hyosung), ROICA and Dorlastan (Asahi Kasei), Linel (Fillattice), and ESPA (Toyobo), incorporated into the fabric to provide stretch. For example, the fabric may contain about 0.1% by weight to about 2.5% by weight, based on the total weight of the fabric, of an antistatic fiber to eliminate or reduce static electricity. For example, the fabric may contain at least one structural fiber selected from the group consisting of aramid polymer, melamine polymer, and combinations thereof. In typical embodiments, the structural fibers are present at about 5-30%, by weight, based on the total weight of the fabric. In certain other embodiments, the structural component is present at about 20-30%, by weight, based on the total weight of the fabric. In other embodiments, the structural component is aramid polymer, such as m-aramid polymer or p-aramid polymer.

The fabrics may be dyed and finished in a conventional manner as described in references such as T. Ishida, An Introduction to Textile Technology, published by Osaka Senken Ltd., Osaka, Japan (1991) and J. H. Marvin, Textile Processing, Volume 1, South Carolina State Department of Education (1973), the disclosures of which are herein incorporated by reference.

The present invention is further defined in the following Examples, in which all parts and percentages are by weight, unless otherwise stated. It should be understood that these examples, while indicating preferred embodiments of the invention, are given by way of illustration only and are not to be construed as limiting in any manner. From the above discussion and these examples, one skilled in the art can ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions.

EXAMPLES Example 1

Two 100% polyester yarns were spun with following denier and staple lengths.

Yarn Denier Staple Length A (invention) multiple multiple (1.11 Dtex, 1.33 Dtex) (32 mm, 38 mm, 44 mm) B (comparative) single single (1.11 Dtex) (38 mm)

A fabric knitted from Yarn A (invention) (Fabric A) (invention) and a fabric knitted from Yarn B (Fabric B) (comparative) were dyed and finished in the same manner. These fabrics were evaluated for their hand/softness and drying time performance as detailed below:

Hand/Softness Evaluation

The hand of the fabrics was evaluated in accordance with American Association of Textile Chemists and Colorists (AATCC) Evaluation Procedure 5 (2011) (Guidelines for the Subjective Evaluation of Fabric Hand). Seven out of ten evaluators rated Fabric A (invention) to be softer than Fabric B (comparative). Of the remaining three evaluators, only one rated Fabric B (comparative) to be softer than Fabric A (invention), while the other two rated Fabric A (invention) and Fabric B (comparative) to be equally soft. Some of the testers noted that Fabric A (invention) felt bulky and/or warm.

Drying Time Performance

The drying times, including wet pickup, total drying time (total to 1% moisture), dry time in comfort zone (20% to 1% moisture), water release rate (WRR) (total to 1% moisture), and WRR in comfort zone (20% to 1% moisture), were measured for Fabric 1 (invention) and Fabric 2 (comparative), in accordance with the AATCC/ASTM Moisture Management Technical Supplement 05 (AATCC/ASTM MM TS-5) gravimetric drying test procedures.

For a typical test, four 2.5×2.5 inch square samples were used. Two of the samples were the “control” (reference) fabric and two were the “test” fabric of interest. Samples were conditioned in the conditioning room at temperature of 70° F. and 65% relative humidity for at least 4 hours prior to test. The samples were then weighed using a laboratory balance, accurate to 0.0001 g to establish the conditioned dry weight. Then 10 mL of distilled water was placed into a 25 ml beaker. Samples were submerged, one sample in the beaker for five to ten minutes, making certain that the sample was completely submerged under the water to insure complete wetting. Even samples exhibiting poor or no horizontal wicking, such as 100 seconds or more horizontal wicking time, absorb water if submerged as described. Samples were then removed from the beaker and sandwiched between two pieces of unused AATCC blotter paper and passed through a wringer (LabPro Padder). The samples were then left sandwiched in the wet blotters until removed and affixed to the vertical samples stand. A vertical sample stand comprising a wire loop supported by a foam base, wherein the top of the wire loop was approximately 15 cm above the top of the base and the parallel wire portions extending from the base were approximately 7.5 cm apart, was used for supporting the samples during drying. The vertical sample stand, and clips were placed on the balance and the balance was tared. The blotted wet sample was attached to the top of the wire loop using the clips, such that the sample hung down within the wire loop. The weight of the sample was recorded to establish a wet weight. The balance was coupled to a data acquisition system comprising Lab View software. Weight readings were automatically recorded every 15 seconds by the computer. The test was complete once the sample weight had reached a designated stopping moisture level versus the conditioned dry weight. The stopping moisture level was approximately 2%. The test was ended by stopping data acquisition in Lab View. The data file was saved for that sample.

Calculation and Interpretation

Total drying time is the time it takes the specimen to reach the stopping weight.

Total water release rate “WRR”, g/min) was calculated as follows:

Total WRR=(wet specimen weight−ending specimen weight)/(total drying time)

WRR_(total) (%) is calculated from the respective total WRR values as follows:

WRR_(total)=100×(WRR_(test)−WRR_(control))/WRR_(control)

The results are shown in the following table:

Dry Time in WRR in Total Drying Comfort Comfort Time (total Zone (20% WRR (Total Zone (20% to 1% to 1% to 1% to 1% Weight Wet Pickup moisture) moisture) moisture) moisture) Fabric (oz/yd²) (%) (min) (min) (g/min) (g/min) B 4.4 26.7 26 18 1.05 1.05 (comparative) A 4.4 27.1 23 16.3 1.19 1.21 (invention) improvement — — 11.5% 9.4% 11.8% 13.2% over comparative

When ranges are used herein for physical properties, such as molecular weight, or chemical properties, such as chemical formulae, all combinations, and subcombinations of ranges specific embodiments therein are intended to be included.

The disclosures of each patent, patent application, and publication cited or described in this document are hereby incorporated herein by reference, in their entirety.

Those skilled in the art will appreciate that numerous changes and modifications can be made to the preferred embodiments of the invention and that such changes and modifications can be made without departing from the spirit of the invention. It is, therefore, intended that the appended claims cover all such equivalent variations as fall within the true spirit and scope of the invention. 

1. A fiber blend, comprising: about 0% by weight to about 15% by weight, based on the total weight of the fiber blend, of a hydrophilic component comprising at least one hydrophilic fiber; and about 85% by weight to about 100% by weight, based on the total weight of the fiber blend, of a hydrophobic component comprising: first synthetic hydrophobic fibers having a first composition; and one or more optional second synthetic hydrophobic fibers having a second composition; wherein at least a portion of said first synthetic hydrophobic fibers have multiple staple lengths and multiple deniers; and wherein said first composition is different than said second composition.
 2. A fiber blend of claim 1, wherein said hydrophilic fibers are cellulose, cellulose derivative, wool, or a combination thereof.
 3. A fiber blend of claim 1, wherein said hydrophilic fiber is cotton or rayon.
 4. A fiber blend of claim 1, wherein said first synthetic hydrophobic fibers are fibers selected from the group consisting of polypropylene, polyester, polyphenylene oxide, polylactide, nylon, polyacrylonitrile, polybenzimidazole, aramid, fluoropolymer, and copolymers thereof.
 5. A fiber blend of claim 1, wherein said at least one second synthetic hydrophobic fibers are present.
 6. A fiber blend of claim 1, wherein said at least one second synthetic hydrophobic fibers are present and said at least one second synthetic hydrophobic fibers are fibers selected from the group consisting of polypropylene, polyester, polyphenylene oxide, polylactide, nylon, polyacrylonitrile, polybenzimidazole, aramid, fluoropolymer, and copolymers thereof.
 7. A fiber blend of claim 1, wherein said first synthetic hydrophobic fibers are fibers selected from the group consisting of poly(ethylene terephthalate), nylon, and modacrylic.
 8. A fiber blend of claim 1, wherein said at least one second synthetic hydrophobic fibers are present and said at least one second synthetic hydrophobic fibers are fibers selected fibers selected from the group consisting of poly(ethylene terephthalate), nylon, and modacrylic.
 9. A fiber blend of claim 1, wherein said hydrophobic component is a single color.
 10. A fiber blend of claim 1, wherein at least a portion of said first synthetic hydrophobic fibers comprise: a first group of fibers having the same staple length and multiple deniers; and a second group of fibers having the same denier and multiple staple lengths; wherein a fiber in said first group may be a fiber in said second group.
 11. A fiber blend of claim 10, wherein said first group of fibers and said second group of fibers are substantially the same color.
 12. A fiber blend of claim 1, wherein at least a portion of said first synthetic hydrophobic fibers comprises: a first group of fibers having a first staple length and a first denier; and a second group of fibers having a second staple length and a second denier; wherein said first staple length is different than said second staple length; and wherein said first denier is different than said second denier.
 13. A fiber blend of claim 12, wherein said first group of fibers and said second group of fibers are substantially the same color.
 14. A fiber blend of claim 1, wherein said hydrophilic component is present at a level of about 10% by weight to about 15% by weight, based on the total weight of the fiber blend; and wherein said hydrophobic component is present at a level of about 85% by weight to about 90% by weight, based on the total weight of the fiber blend.
 15. A fiber blend of claim 1, wherein said first synthetic hydrophobic fibers comprises: about 10% by weight to about 90% by weight, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a first denier; about 10% by weight to about 90% by weight, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a second denier; wherein said first denier is different from said second denier; and about 0% by weight to about 80% by weight, based on the total weight of the first synthetic hydrophobic fibers, of at least one fiber having an additional denier different than said first denier, second denier, and any said additional deniers, if present.
 16. A fiber blend of claim 1, wherein said first synthetic hydrophobic fibers comprise: about 10% by weight to about 90% by weight, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a first staple length; about 10% by weight to about 90% by weight, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a second staple length; wherein said first staple length is different from said second staple length; and about 0% by weight to about 80% by weight, based on the total weight of the first synthetic hydrophobic fibers, of at least one fiber having an additional staple length different than said first staple length, second staple length, and any said additional staple lengths, if present.
 17. (canceled)
 18. (canceled)
 19. A fiber blend of claim 1, wherein said first synthetic hydrophobic fibers comprise: about 20 weight % to about 80 weight %, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a first denier; about 20 weight % to about 80 weight %, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a second denier; and about 0 weight % to about 60 weight %, based on the total weight of the first synthetic hydrophobic fibers, of at least one fiber having an additional denier different than said first denier, second denier, and any said additional deniers, if present.
 20. A fiber blend of claim 1, wherein said first synthetic hydrophobic fibers comprise: about 20 weight % to about 80 weight %, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a first staple length; about 20 weight % to about 80 weight %, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a second staple length; and about 0 weight % to about 60 weight %, based on the total weight of the first synthetic hydrophobic fibers, of at least one fiber having an additional staple length different than said first staple length, second staple length, and any said additional staple lengths, if present.
 21. (canceled)
 22. A fiber blend of claim 1, wherein said fiber blend is substantially intimately blended.
 23. A fiber blend, comprising: about 0% by weight to about 15% by weight, based on the total weight of the fiber blend, of cotton fibers; and about 85% by weight to about 100% by weight, based on the total weight of the fiber blend, of polyethyleneterephthalate fibers; wherein at least a portion of said polyester fibers have multiple staple lengths and multiple deniers.
 24. A fiber blend, comprising: about 15% by weight, based on the total weight of the fiber blend, of cotton fibers; about 75% by weight, based on the total weight of the fiber blend, of modacrylic fibers; about 10% by weight, based on the total weight of the fiber blend, of nylon fibers; wherein at least a portion of said modacrylic fibers, at least a portion of said nylon fibers, or at least a portion of both of said modacrylic fibers and said nylon fibers have multiple staple lengths and multiple deniers.
 25. A yarn, comprising the fiber blend of claim
 1. 26. A yarn of claim 25, wherein said yarn is a spun yarn.
 27. A yarn of claim 25, further comprising: at least one antistatic fiber.
 28. A fabric, comprising the yarn of claim
 25. 29. A fabric of claim 28, wherein said fabric meets the requirement for flame resistance, as set forth in American Society for Testing and Materials Standard Performance Specification ASTM F1506.
 30. A fabric of claim 28, wherein said fabric has a water release rate at least about 10% greater than a comparative fabric, as said fabric dries from 20% by weight water to 1% by weight water, when tested in accordance with a modified version of the provisional AATCC Gravimetric Drying Test Method (AATCC/MM TS-05); and wherein said comparative fabric is compositionally identical to said fabric and whose hydrophobic fibers are not both of multiple staple lengths and multiple deniers.
 31. A fabric of claim 28, wherein said fabric has a water release rate at least about 10% greater than a comparative fabric, as said fabric is dried from a condition of wet (padded) to less than 1% by weight water, when tested in accordance with a modified version of the provisional AATCC Gravimetric Drying Test Method (AATCC/MM TS-05); and wherein said comparative fabric is compositionally identical to said fabric and whose hydrophobic fibers are not both of multiple staple lengths and multiple deniers.
 32. A fabric of claim 28, wherein said fabric has a drying time at least 10% faster than a comparative fabric from 20% by weight water to 1% by weight water in a controlled environment of 70° F. and 55% relative humidity (+/−5% relative humidity), when tested in accordance with a modified version of the provisional AATCC Gravimetric Drying Test Method (AATCC/ASTM MM TS-05); and wherein said comparative fabric is compositionally identical to said fabric and whose hydrophobic fibers are not both of multiple staple lengths and multiple deniers.
 33. A garment, comprising the fabric of claim
 28. 34. A linen, comprising the fabric of claim
 28. 35. A method of improving the moisture management properties of a fiber blend, comprising: intimately blending: about 0% by weight to about 15% by weight, based on the total weight of the fiber blend, of a hydrophilic component comprising at least one hydrophilic fiber; and about 85% by weight to about 100% by weight, based on the total weight of the fiber blend, of a hydrophobic component comprising: first synthetic hydrophobic fibers having a first composition; and one or more optional second synthetic hydrophobic fibers having a second composition; wherein at least a portion of said first synthetic hydrophobic fibers have multiple staple lengths and multiple deniers. 